Storage container with removable locking tabs

ABSTRACT

A merchandise storage container has a holder that moves into and out of an outer sleeve. At least one locking tab portion is used to secure the holder inside the sleeve. The locking tab portion may be removed to unlock the tray and allow the user to access the contents of the tray.

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. provisional patentapplications 61/044,117 filed Apr. 11, 2008 and 61/045,909 filed Apr.17, 2008; the disclosures of which are incorporated herein by reference.

BACKGROUND OF THE INVENTION

1. Technical Field

The present invention generally relates to storage containers and, moreparticularly, to tamper-evident merchandise storage containers.Specifically, the invention relates to a merchandise storage containerhaving a storage tray and a sleeve wherein the tray is initially securedinside the sleeve by at least one removable locking tab.

2. Background Information

Various merchandise storage containers are known in the art. Some of themost common merchandise storage containers for recorded media arebook-like containers having a lid connected to a base with a hinge. Someof these containers include latches designed to keep the lid closed withrespect to the base until the latches are moved to an unlatchedconfiguration. Another type of merchandise storage container includes amerchandise holder disposed within an outer sleeve. The holder slidesout of the sleeve to provide access to the merchandise. Those who usethis container configuration desire a device that prevents the tray frombeing slid out of the sleeve and functions to indicate if the containerhas ever been opened.

BRIEF SUMMARY OF THE INVENTION

The invention provides a storage container having a merchandise holderthat moves into and out of an outer sleeve. At least one locking tabportion is used to secure the holder inside the sleeve. The locking tabportion may be removed from the sleeve to unlock the holder and allowthe user to access the contents of the holder.

In one configuration of the merchandise storage container, a merchandiseholder is held within a sleeve by at least one locking tab. Themerchandise holder is provided in a configuration designed to receivethe item of merchandise to be received in the container. For example,the holder may be a tray, a sleeve, a box, an envelope, or a combinationof structures. Each of the holder and sleeve includes a locking tabportion. The locking tab portions may be integral to the holder orsleeve or connected to the holder and sleeve after the holder or sleeveis formed. The locking tab portions are disposed adjacent to each otherwhen the holder is disposed within the sleeve. The locking tab portionsare connected together to secure the holder in place within the sleeve.When the user wants access to the holder, the user tears or breaks thejoined locking tab portions away from the container to unlock the tray.

Another configuration of the invention provides a releasable adhesivethat releasably holds the joined locking tab portions against the outersurface of the sleeve until the user is ready to tear the locking tabaway from the container.

Another configuration of the invention uses a line of severance orperforations formed between the container and the locking tab.

In one exemplary configuration, the sleeve and the holder are fabricatedfrom paperboard with the locking tab portions being integrally formedfrom the same paperboard blanks. A permanent adhesive secures thelocking tab portions together to form a locking tab. A releasableadhesive is used to hold the locking tab to an outer portion of thesleeve. The releasable adhesive does not damage the surface of thecontainer to which the locking tab is attached so that the removal ofthe locking tab from the container does not leave a visible blemish onthe container.

These configurations and features are provided individually and incombination with one another to form additional configurations. Examplesof the invention are described below. The invention is defined by theclaims.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

FIG. 1 is a front perspective view of a first configuration for amerchandise storage container in the closed configuration with thelocking tabs held against the sleeve.

FIG. 2 is a front perspective view of the first configuration with thelocking tabs peeled away from the surfaces of the sleeve.

FIG. 3 is a top plan view of one of the locking tabs of FIG. 2.

FIGS. 3A and 3B are schematic views of locking tab portions connectedtogether with mechanical connectors.

FIG. 4 is a front elevation view of the locking tab of FIG. 3 showingthe perforations between the locking tab and the container.

FIG. 5 is a front perspective view of the first configuration with thelocking tabs removed and the holder partially slid out to an extendedposition.

FIG. 6 is a front perspective view of the first configuration with thelocking tabs removed and the holder slid out to an extended position.

FIG. 7 is a front perspective view of the base of the holder showing therelationship between the locking flange of the holder and the storagenest for a media disc.

FIG. 8 is a view similar to FIG. 3 showing the locking tab portionsindividually.

FIG. 9 is a layout view of a blank that may be used to form the sleeve.

FIG. 10 is a layout view of a blank that may be used to form the holder.

FIG. 11 is a perspective view of an alternative configuration of themerchandise holder having a hold-down projection disposed against aportion of a media disc while the cover is being opened.

FIG. 12 is a layout view of a blank used to form the configuration ofthe merchandise holder of FIG. 11.

Similar numbers refer to similar, but not necessarily identical, partsthroughout the specification.

DETAILED DESCRIPTION OF THE INVENTION

A first configuration of the storage container is indicated generally bythe numeral 2 in the accompanying drawings. The first configuration ofcontainer 2 includes an outer sleeve 4 and an internal merchandiseholder 6 that moves between retracted (FIGS. 1 and 2) and extended (FIG.6) positions. Merchandise holder 6 may be configured to hold any of avariety of merchandise items. In the exemplary configuration depicted inthe drawings, holder 6 is configured to hold at least one disc-shapeditem of recorded media such as a DVD or a CD. In other configurations,holder 6 may be configured to hold a tape, a cartridge, a UMD, a memorycard or memory chip, or other types of media. Holder 6 also may beconfigured to hold items of merchandise such as gift cards, bank cards,hearing aids, media players, jewelry, watches, and small batteries. Thethickness of holder 6 may be increased so that container 2 may be usedwith thicker merchandise such as razor blades, batteries, mobile phones,personal health care items, small consumer electronic devices, and thelike. When a media disc is held by holder 6, holder 6 may hold the mediadisc in any of a variety of manners such as a snap hub that engages thecentral opening of item or a partially covered nest as depicted in FIGS.6 and 11. Container 2 is used to provide a plurality of interactivegraphic display areas which may be used to display information relatedto the item stored within container 2.

The holder may be fabricated by injection molding, a thermo or vacuumforming, pressing, metal forming, folding, and the like. The holder maybe made from a plastic, an acrylic, a polycarbonate, a polypropylene, arecycled material such as a plastic, a paper or a molded paper-pulpproduct, a metal, a paperboard, a foam, and the like.

In the exemplary configuration depicted in the drawings and describedbelow, the entire container 2 is manufactured from a paper-based productsuch as a paperboard. When container 2 is to be discarded, the entirecontainer may be recycled. In the exemplary configuration, sleeve 4 is afive-sided sleeve defining an opening along one of its long walls. Inother configurations, sleeve 4 may define its opening along a shortwall. Outer sleeve 4 may define a finger access cutout 12 in its frontand rear panels that allow the user to grasp and pull on internalmerchandise holder 6. As shown in FIG. 9, cutout 12 is also defined by alocking flange 18 and an entrance flange 19. FIG. 9 depicts the blankused to form outer sleeve 4. The blank may be cut or punched frommaterial stock, folded along the lines depicted in FIG. 9, and glued toform sleeve 4.

Flange 18 may include tapered ends 30 and an indented central portion32. The tapered portion of flange 18 reduces binding between the twolocking flanges 18 and 20 when holder 6 is inside sleeve 4. The taperedportion of flange 18 also prevents flange 18 from binding against theinner surfaces of the side walls of sleeve 4. Indented central portion32 reduces binding between flange 18 and flange 20. Entrance flange 19is folded inwardly and secured inside sleeve 4. Folding flanges 18 and19 inwardly provides smooth edges to the opening of sleeve 4 as depictedin FIG. 4. The smooth edges are formed by bending the outer layer of thepaperboard material without slitting or perforating. Bending provides asmooth surface for the insertion of holder 6 and an appealing appearanceto container 2.

Flanges 18 and 20 interact to prevent internal holder 6 from beingcompletely pulled from sleeve 4 during normal use. Flanges 18 and 20 maybe sized to stop holder 6 from being pulled out of sleeve 4 immediatelyafter the merchandise held by holder 6 is exposed to the user forremoval.

FIG. 10 shows the use of multiple layers of material to form a nest onholder 6. As shown in FIG. 10, the material used to form holder 6 isthicker than the material used to form sleeve 4. The thicker materialprovides rigidity to container 2. The material also allows the nest tobe built up to be thicker than the thickness of the media disc with onlyan inner nest page 40 and an outer nest page 42. When assembled, innernest page 40 is folded over at a fold line 43 to be disposed directedagainst backing page 44. Backing page 44 may include a disc hub ifdesired. Outer nest page 42 is folded over about a fold line 45 on topof inner nest page 40 to form a nest. Backing page 44 is connected to aspine 79 that is connected to an optional cover 46. Cover 46 is definedby a pair of cover panels that are folded against each other and heldwith an adhesive. Cover 46 may be used to cover a portion of themerchandise held by holder 6 and may be used to help retain holder 6within sleeve 4 after locking tabs 70 are removed. Spine 79 is exposedwhen holder 6 is disposed within sleeve 4 as shown in FIGS. 1-4.

Opposite spine 79, flange 20 is connected to page 44 by a pair of spacedliving hinges 50 that allow flange 20 to fold over pages 40, 42, 44, and54 as shown in FIG. 7. Flange 20 is formed from a portion of page 40.Flange 20 defines a central notch 51 that is aligned with opening 12.Flange 20 also defines a pair of notches 52 that increase the portion ofthe circumference of the nest that is formed from page 40. Notches 52also prevent flange 20 from overlapping the nest as shown in FIG. 7. Inthe exemplary configuration, page 54 defines an overlap lip 56 that mayan embossed portion of page 54. Lip 56 extends over a portion of a mediadisc disposed in the nest to prevent the disc from immediately fallingout of the nest.

Container 2 is used to provide a plurality of interactive graphicdisplay areas and panels which may be used to display informationrelated to the item of recorded media stored within container 2.

Container 2 includes at least one locking tab 70 that is used to secureholder 6 within sleeve 4 until the user wishes to use container 2. Inthe exemplary configuration, container 2 uses a pair of locking tabs 70to secure holder 6 within sleeve 4. Locking tabs 70 may be disposed onopposite ends of holder 6 as shown in the drawings. Locking tabs 70 alsomay be disposed at opposite sides (as indicated by dashed lines 72 inFIG. 1) of holder 6.

Each locking tab 70 is formed by joining locking tab portions 74 and 76from sleeve 4 and holder 6. Locking tab portions 74 are integrallyformed with end walls 78 of sleeve 4 as shown in FIG. 9. Locking tabportions 76 are integrally formed with a spine 79 of holder 6 as shownin FIG. 10.

When holder 6 is initially slid inside sleeve 4, locking tab portions 74and 76 are connected together. Portions 74 and 76 may be connected witha mechanical connector such as a staple or a rivet. They also may beconfigured to be welded, woven or locked together mechanically. Forexample, one locking tab portion may include a protuberance with a catchdesigned for a one-way snap fit connection that snaps into an openingdefined by the other locking tab portion. In the exemplaryconfiguration, portions 74 and 76 are connected with an adhesive. Theadhesive may be an adhesive designed to strong bond with the material ofportions 74 and 76 to provide a “permanent” bond between portions 74 and76. Such a bond would likely result in the tearing of one of portions 74or 76 or at least the damaging of a surface if one were to forceportions 74 and 76 apart. During or after formation, each locking tab 70may be folded down against an outer surface of sleeve 4 so that lockingtabs 70 do not protrude from container 2. This position is shown inFIG. 1. Tabs 70 may be held down with a “low-tack” pressure sensitiveadhesive strong enough to hold tabs 70 down against sleeve 4 but notstrong enough to blemish the outer surface coating or surface finish ofsleeve 4 when tabs 70 are peeled away from sleeve. Such an adhesive isreferred to as a releasable adhesive. Mechanical snap connectors alsomay be used to hold tabs 70 in this position. In the exemplaryconfiguration, tabs 70 are adhesively secured to the end walls 78 ofsleeve 4.

When the user wishes to remove holder 6 from sleeve 4, the user peelstabs 70 away from sleeve 4 as depicted in FIG. 2. The user may then teartabs 70 away from container 2 as shown in FIG. 5. To facilitate thetearing, perforations 80 may be defined by tabs 70. Once tabs 70 aretorn away, holder 6 may be slid (in the exemplary configuration) orrotated/pivoted (in other examples) out of sleeve 4.

An alternative configuration uses only at least one tab portion 76 thatis anchored to sleeve 4 to prevent opening of the holder or to show thatthe holder has been opened. Tab portion 76 may be secured with areleasable low tack adhesive, a permanent adhesive, or a mechanicalconnection (such as a staple, cooperating snap fit connector elements, arivet). In this configuration, the user may unlock holder 6 by breakingor severing tab portion 76 or by peeling portion 76 away from sleeve 4.

FIGS. 11 and 12 depict an alternative configuration for holder 6 whereina hold-down projection 90 is used to help keep a media disc seatedwithin the nest of holder 6. This configuration of holder 6 may be usedas a part of container 2 when it is formed to have locking tab portions76 as described above. In FIGS. 11 and 12, holder 6 is shown withoutlocking tab portions 76. This configuration may be used with a sleeve 2without locking tab portions to provide another configuration of acontainer.

Hold-down projection 90 is connected to the inner portion of cover 46 asshown in FIG. 12. Projection 90 is hinged to the end of the inner cover46A so that the projection 90 pivots about an axis parallel to the pivotaxis of cover 46. When cover is formed, the hinge for projection 90 isdisposed next to the hinge connecting spine 79 to cover 46.

In use, projection 90 is folded back against the inner surface of cover46 (the inner surface being the one that faces the nest when cover 46 isclosed) so that it is trapped between the inner surface of cover 46 andthe outer surface of panel 54. Projection 90 is sized to cover a portionof the media disc when cover 46 is closed. Projection 90 thus providesan additional thickness of material between the bottom of the nest andthe inner surface of cover 46. This thickness helps maintain the mediadisc in the nest when holder 6 is closed. Projection 90 is folded abouta living hinge that retains a degree of memory so that projection 90will tend to be urged outwardly from the inner surface of cover 46 ascover 46 is opened as depicted in FIG. 11. Projection 90 thus helps keepthe media disc from falling out of the nest when cover 46 is beingopened. Projection 90 thus cooperates with lip 56 to maintain the mediadisc in the nest.

In the foregoing description, certain terms have been used for brevity,clearness, and understanding. No unnecessary limitations are to beimplied therefrom beyond the requirement of the prior art because suchterms are used for descriptive purposes and are intended to be broadlyconstrued.

Moreover, the description and illustration of the invention is anexample and the invention is not limited to the exact details shown ordescribed.

1. A merchandise storage container comprising: an outer paperboardsleeve having an outer surface; a merchandise holder carried by theouter paperboard sleeve; the merchandise holder being movable betweenretracted and extended positions; the merchandise holder being disposedinside the outer paperboard sleeve when the merchandise holder is in theretracted position; and at least one locking tab securing themerchandise holder in the retracted position; the locking tab having afirst paperboard locking tab portion integrally connected to the outerpaperboard sleeve and a second locking tab portion connected to themerchandise holder; the first and second locking tab portions beingconnected together.
 2. The container of claim 1, wherein the locking tabis adhered to the outer surface of the outer paperboard sleeve with areleasable adhesive.
 3. The container of claim 2, wherein the lockingtab portions are adhered together.
 4. The container of claim 1, whereinthe locking tab defines perforations adjacent the outer paperboardsleeve that allow the locking tab to be torn away from the sleeve.
 5. Amerchandise storage container comprising: an outer sleeve having anouter surface; a merchandise holder carried by the outer sleeve; themerchandise holder being movable between retracted and extendedpositions; the merchandise holder being disposed inside the outer sleevewhen the merchandise holder is in the retracted position; and at leastone locking tab securing the holder in the retracted position; thelocking tab including first and second locking tab portions that areconnected together; the first locking tab portion extending from thesleeve and the second locking tab portion extending from the holder. 6.The container of claim 5, wherein the locking tab portions are connectedtogether with an adhesive.
 7. The container of claim 5, wherein thelocking tab is adhered to the outer surface of the sleeve with areleasable adhesive.
 8. The container of claim 5, wherein the lockingtab defines perforations that allow the locking tab to be torn away fromthe sleeve.
 9. The container of claim 5, wherein one of the sleeve andholder are formed from paperboard.
 10. The container of claim 5, whereinthe holder is fabricated from plastic.
 11. The container of claim 10,wherein the second locking tab portion is fabricated from plastic. 12.The container of claim 5, wherein the holder is fabricated from one of ametal, a plastic, a molded paper pulp product, and a paper material. 13.The container of claim 5, wherein the sleeve is fabricated from one of ametal, a plastic, a molded paper pulp product, and a paper material. 14.The container of claim 5, wherein the locking tab portions are connectedtogether with a mechanical connector.
 15. The container of claim 5,wherein the locking tab portions are connected together with a one-waysnap fit connector.
 16. The container of claim 5, wherein the holderdefines a nest and a cover for the nest; the cover including aprojection sized to overlie a portion of the nest when the cover isclosed.
 17. The container of claim 5, wherein the cover of the holdermoves between open and closed positions about a cover hinge; theprojection being hinged to the cover close to the cover hinge.
 18. Amerchandise storage container comprising: an outer sleeve having anouter surface; a merchandise holder movably carried by the outer sleevebetween retracted and extended positions; the merchandise holder beingdisposed inside the outer sleeve when the merchandise holder is in theretracted position; at least one locking tab portion connected to themerchandise holder; and the locking tab portion being anchored to theouter sleeve; the locking tab portion securing the merchandise holder inthe retracted position.
 19. The container of claim 18, wherein the outersleeve is fabricated from paperboard.